Method and apparatus for forming tooling and associated materials therefrom

Abstract

Described herein is a method of forming tooling used to form a material. The method includes positioning a first susceptor made from a first susceptor material between first and second dies. At least one of the first and second dies includes a forming surface having a desired shape. The method further includes positioning a second susceptor made from a second susceptor material between the first and second dies such that the first susceptor is interposed between the second susceptor and the forming surface. Additionally, the method includes positioning a first bladder between the first and second dies such that the second susceptor is interposed between the first bladder and the first susceptor. Also, the method includes inflating the first bladder to concurrently deform the first susceptor and second susceptor into the desired shape.

What is claimed is: 
     
       1. A method of forming tooling used to form a material, comprising:
 positioning a first susceptor made from a first susceptor material between first and second dies, wherein at least one of the first and second dies comprises a forming surface having a desired shape; 
 positioning a second susceptor made from a second susceptor material between the first and second dies such that the first susceptor is interposed between the second susceptor and the forming surface, wherein the first susceptor material has a first Curie temperature that is higher than a deformation temperature of the second susceptor material; 
 positioning a first bladder between the first and second dies such that the second susceptor is interposed between the first bladder and the first susceptor; and 
 inflating the first bladder to concurrently deform the first susceptor and second susceptor into the desired shape. 
 
     
     
       2. The method of  claim 1 , wherein the second susceptor material has a second Curie temperature lower than the first Curie temperature, the method further comprising applying a magnetic field to the first susceptor to heat via induction the first susceptor to at least the first Curie temperature prior to inflating the first bladder. 
     
     
       3. The method of  claim 2 , wherein the first and second dies each comprises embedded electromagnetic coils, the magnetic field being generated by at least one of the electromagnetic coils. 
     
     
       4. The method of  claim 1 , wherein the first susceptor material comprises a low-carbon steel and the second susceptor material comprises a nickel-iron-molybdenum alloy. 
     
     
       5. The method of  claim 1 , further comprising positioning a caul sheet between the first and second dies such that the second susceptor is interposed between the caul sheet and the first susceptor and the caul sheet is interposed between the first bladder and the second susceptor, wherein inflating the first bladder concurrently deforms the first susceptor, second susceptor, and caul sheet into the desired shape. 
     
     
       6. The method of  claim 5 , wherein the caul sheet is made from a material having a coefficient of thermal expansion (CTE) less than about 7×10 −4  in/in/° F. 
     
     
       7. The method of  claim 5 , wherein the caul sheet is made from a nickel-iron alloy. 
     
     
       8. The method of  claim 5 , wherein:
 the first susceptor comprises a first sheet and a second sheet; 
 the second susceptor comprises a third sheet and a fourth sheet interposed between the first sheet and second sheet of the first susceptor; 
 the caul sheet is interposed between the third sheet and fourth sheet of the second susceptor; 
 the first bladder is interposed between the third sheet of the second susceptor and the caul sheet; 
 deformation of the first susceptor comprises deforming the second sheet of the first susceptor into the desired shape; and 
 deformation of the second susceptor comprises deforming the fourth sheet of the second susceptor into the desired shape. 
 
     
     
       9. The method of  claim 5 , further comprising moving the first and second dies toward each other to enclose the first susceptor, second susceptor, caul sheet, and first bladder between the first and second dies prior to inflating the first bladder. 
     
     
       10. A method of forming a component made from a composite material, comprising:
 positioning a first susceptor made from a first susceptor material between first and second dies, wherein at least one of the first and second dies comprises a forming surface having a desired shape; 
 positioning a second susceptor made from a second susceptor material between the first and second dies such that the first susceptor is interposed between the second susceptor and the forming surface; 
 positioning a caul sheet between the first and second dies such that the second susceptor is interposed between the caul sheet and the first susceptor; 
 positioning a first bladder between the first and second dies such that the caul sheet is interposed between the first bladder and the second susceptor; 
 inflating the first bladder to concurrently deform the first susceptor, second susceptor, and caul sheet into the desired shape; 
 after inflating the first bladder to deform the first susceptor, second susceptor, and caul sheet into the desired shape, removing the first susceptor and first bladder from between the first and second dies; 
 after removing the first susceptor and first bladder from between the first and second dies:
 positioning an unconsolidated composite material between the first and second dies such that the caul sheet is interposed between the unconsolidated composite material and the second susceptor; and 
 positioning a second bladder between the first and second dies such that the unconsolidated composite material is interposed between the second bladder and the caul sheet; and 
 
 inflating the second bladder to deform the unconsolidated composite material into the desired shape. 
 
     
     
       11. The method of  claim 10 , wherein the first susceptor material has a first Curie temperature and the second susceptor material has a second Curie temperature lower than the first Curie temperature, the method further comprising applying a first magnetic field to the first susceptor to heat via induction the first susceptor to the first Curie temperature prior to inflating the first bladder. 
     
     
       12. The method of  claim 11 , wherein after removing the first susceptor and first bladder from between the first and second dies, the method further comprising applying a second magnetic field to the second susceptor to heat via induction the second susceptor to the second Curie temperature prior to inflating the second bladder. 
     
     
       13. The method of  claim 12 , wherein the first and second dies each comprises embedded electromagnetic coils, the first and second magnetic fields being generated by at least one of the electromagnetic coils. 
     
     
       14. The method of  claim 12 , wherein the unconsolidated composite material is configured to melt at a melting temperature, the second Curie temperature being at least as high as the melting temperature of the unconsolidated composite material. 
     
     
       15. The method of  claim 10 , wherein prior to positioning the unconsolidated composite material between the first and second dies, the method comprises pre-configuring the unconsolidated composite material into a shape complementing the desired shape. 
     
     
       16. The method of  claim 10 , wherein the first bladder is made from a first material and the second bladder is made from a second material different than the first material. 
     
     
       17. The method of  claim 16 , wherein the first bladder is made from a low-carbon steel and the second bladder is made from an aluminum alloy. 
     
     
       18. The method of  claim 10 , wherein:
 the caul sheet has a first coefficient of thermal expansion (CTE) and the thermoplastic composite material has a second CTE; and 
 the first CTE is between about 0.9 and about 1.1 times the second CTE. 
 
     
     
       19. The method of  claim 10 , wherein:
 the second susceptor comprises a first sheet and a second sheet; 
 the caul sheet is interposed between the first sheet and second sheet of the second susceptor; 
 the second bladder is interposed between the first sheet and second sheet of the second susceptor; and 
 the unconsolidated composite material is interposed between the second sheet of the second susceptor and the second bladder.